JP2021062839A - Vehicle interior member and manufacturing method of the same - Google Patents

Abstract

To provide a vehicle interior member in which a fastening part, such as a clip attachment seat, is securely joined to a trim body without using a separate member such as a cushion material or a seat material.SOLUTION: A vehicle interior member 1 includes: a trim body 2 having a foam material layer 10; and a fastening part 3 which fastens the vehicle interior member 1 and a mating member to each other and is harder than the foam material layer 10. The fastening part 3 includes: a body part 30 having a bottom surface 32 facing a surface 11 of the foam material layer 10; and protruding parts (50) protruding from the bottom surface 32 into the foam material layer 10. Each protruding part (50) includes: a base part 60 connected to the bottom surface 32; and protrusion parts 70 protruding from the base part 60 in directions (D1, D2) different from a protruding direction D0 of the base part 60 protruding from the bottom surface 32.SELECTED DRAWING: Figure 4

Description

The present invention relates to an interior member for a vehicle and a method for manufacturing the same.

In an automobile in which the vehicle body is formed of steel plate panels, interior members such as door trims cover the steel plate panels to decorate the interior, impart soundproofing to the passenger compartment, and enhance the safety of the passenger compartment. The interior member has, for example, a foamed resin layer, a skin material arranged on the front side, and a plurality of clip mounting seats arranged on the back side. A base end of a resin clip for attaching an interior member to a vehicle body is attached to each clip attachment seat.
In Patent Document 1, a cushion material to which a sheet material is adhered is adhered to the back surface of a bracket as a clip mounting seat, and these are placed in a mold to foam a foamed resin stock solution, whereby the bracket or the like is placed in a foamed resin base material. It has been shown to manufacture integrally embedded door trims. Here, the cushion material is used so that the base end of the fastener as a clip can be inserted on the back side of the bracket, and the sheet material is adhered to the surface of the cushion material on the back side of the bracket. This is to slide the base end of the fastener to a predetermined position.

Jikkenhei 6-8028 Gazette

The above-mentioned door trim requires a cushion material and a seat material. Such problems also exist in interior members other than door trims, such as deck side trims and roof trims.

The present invention discloses an interior member for a vehicle in which a fastening portion such as a clip mounting seat is firmly joined to the trim body without using a separate member such as a cushion material or a seat material, and a method for manufacturing the same. ..

The vehicle interior member of the present invention
A trim body with a foam material layer and
A fastening portion between the vehicle interior member and the mating member, which is harder than the foam material layer, is provided.
The fastening part is
A main body having a bottom surface facing the surface of the foam material layer,
Includes a plurality of protrusions protruding from the bottom surface into the foam material layer.
The protrusion is
The base connected to the bottom surface and
It has an embodiment including a protruding portion protruding from the base portion in a direction different from the protruding direction of the base portion from the bottom surface.

Further, the method for manufacturing an interior member for a vehicle according to the present invention is as follows.
The vehicle interior member includes a trim body having a foam material layer, and a fastening portion between the vehicle interior member and a mating member, which is harder than the foam material layer.
The fastening portion includes a main body portion having a bottom surface and a plurality of projecting portions protruding from the bottom surface.
The protruding portion includes a base portion connected to the bottom surface and a protruding portion protruding from the base portion in a direction different from the protruding direction of the base portion from the bottom surface.
The embodiment includes a step of inserting the plurality of protruding portions into the foam material layer by pressing the fastening portion with the bottom surface facing the surface of the foam material layer against the surface of the foam material layer.

According to the present invention, it is possible to provide an interior member for a vehicle in which functional parts such as a fastening portion are firmly joined to the trim body without using a separate member such as a cushion material or a seat material.

The figure which shows typically the example of the interior of an automobile in a state where the illustration of a side part is omitted. The figure which shows typically the example of the back surface of an interior member. The perspective view which shows typically the example of the fastening part and its surroundings. The figure which shows typically the example of the cross section when the fastening part and the periphery thereof are cut at the position A1 of FIG. FIG. 5A is a side view schematically showing an example of a clip attached to a clip mounting seat, and FIG. 5B is a cross-sectional view schematically showing an example of a main part of an automobile having a hook portion. The perspective view which shows typically the example of the bottom part and the hook in the fastening part. The figure which shows typically the example of the hook seen from the direction along the bottom surface. The figure which shows typically the example of the hook seen from the direction orthogonal to the bottom surface. The figure which shows typically the example of the hook contained in the foam material layer. The figure which shows typically the example of the process of joining a fastening part to a trim body. FIG. 11A is a diagram schematically showing an example of a cross section of the fastening portion when the surface of the foam material layer has a recess and a cross section around the fastening portion, and FIG. 11B shows the bottom surface of the main body portion separated from the surface of the foam material layer. The figure which shows typically the example of the cross-section of the fastening part of the case and the periphery thereof. 12A and 12B are perspective views schematically showing another example of the fastening portion. 13A and 13B are diagrams schematically showing another example of the protruding portion viewed from the direction along the bottom surface. The figure which shows typically the example of the evaluation apparatus of a tensile test.

Hereinafter, embodiments of the present invention will be described. Of course, the following embodiments merely exemplify the present invention, and not all of the features shown in the embodiments are essential for the means for solving the invention.

(1) Outline of the technique included in the present invention:
First, an outline of the technique included in the present invention will be described with reference to the examples shown in FIGS. 1 to 14. It should be noted that the figures of the present application are diagrams schematically showing examples, and the enlargement ratios in each direction shown in these figures may be different, and the figures may not be consistent. Of course, each element of the present technology is not limited to the specific example indicated by the reference numeral.
Further, in the present application, the numerical range "Min to Max" means a minimum value of Min or more and a maximum value of Max or less.

[Aspect 1]
The vehicle interior member 1 according to one aspect of the present technology is a fastening portion 3 between a trim body 2 having a foam material layer 10 and the vehicle interior member 1 and a mating member (for example, a vehicle body panel 80), and the foaming. A fastening portion 3 that is harder than the material layer 10 is provided. The fastening portion 3 includes a main body portion 30 having a bottom surface 32 facing the front surface 11 of the foam material layer 10 (for example, the back surface 2b of the trim body 2), and a plurality of fastening portions 3 protruding from the bottom surface 32 into the foam material layer 10. Includes a protrusion (eg, hook 50). The protruding portion (50) is formed in a direction different from the base portion 60 connected to the bottom surface 32 and the protruding direction D0 of the base portion 60 from the bottom surface 32 (for example, the first direction D1 and the second direction D2). It includes a protrusion 70 protruding from 60.

In the first aspect, the base 60 is projected from the bottom surface 32 of the fastening portion 3 into the foam material layer 10 of the trim body 2 in a direction (D1, D2) different from the protruding direction D0 of the base 60. Since there is a protruding portion 70 protruding from the above, the trim main body 2 and the fastening portion 3 are firmly joined even if the main body portion 30 of the fastening portion 3 is not embedded in the foam material layer 10. Therefore, in this aspect, it is possible to provide an interior member for a vehicle in which a fastening portion is firmly joined to the trim body without using a separate member such as a cushion material or a seat material.

Here, the fastening portion includes a clip mounting seat for attaching the interior member to the mating member (for example, a vehicle body panel) via an elastic clip, a portion for mounting the mating member to the interior member, and the like. The fastening portion may be relatively hard as compared with the foamed material layer, and is not limited to a non-foamed material, and may be a material having a foaming ratio lower than that of the foamed material layer.
The bottom surface facing the surface of the foam material layer may be in contact with the surface of the foam material layer or may be separated from the surface of the foam material layer.
The shape of the protruding portion having the protruding portion includes a hook shape, a mushroom shape, and the like.
The above-mentioned additional notes are also applied in the following aspects.

[Aspect 2]
As illustrated in FIGS. 6 to 8 and the like, the protrusion 70 has a first direction protrusion 71 protruding from the base 60 in the first direction D1 and the first direction when projected onto the bottom surface 32. A second direction protrusion 72 protruding from the base 60 may be included in the second direction D2 different from D1. The protrusion (50) may include the first-direction protrusion 71 and the second-direction protrusion 72. In this embodiment, since the first-direction protrusion 71 and the second-direction protrusion 72 having different orientations are located at the protrusion (50), the joint strength between the trim body and the fastening portion can be improved.

The terms "first", "second", "third", ... In the present application are terms for identifying each component included in a plurality of components having similarities to each other, and do not mean the order. .. Which of the plurality of components corresponds to "first", "second", "third", ... Is relatively determined.
The above-mentioned additional notes also apply in the following aspects.

[Aspect 3]
Here, as illustrated in FIG. 8 and the like, the direction along the bottom surface 32 and intersecting the first direction D1 and the second direction D2 when projected onto the bottom surface 32 is the third direction D3. And. The base 60 is a first section 61 connected from the bottom surface 32 to the first direction protrusion 71, and a second direction protrusion from the bottom surface 32 in the first section 61 to the third direction D3. The second division 62, which leads to 72, may be included. The base 60 may include a third section 63 between the first section 61 and the second section 62. The first-direction protrusion 71 and the second-direction protrusion 72 may be separated from each other in the third direction D3. In this embodiment, the bonding strength between the trim body and the fastening portion can be further improved by allowing the foam material to enter between the first-direction protrusion portion and the second-direction protrusion portion.

[Aspect 4]
Further, the ratio S1 / V1 (mm ^{-1 ) of the surface areas S1 (mm 2} ) of the plurality of protrusions (50) to the volume V1 (mm ³ ) of the plurality of protrusions (50) may be 10 or less. As a result of repeated tests, it was found that the joint strength between the trim body 2 and the fastening portion 3 was improved by setting S1 / V1 ≦ 10. Therefore, this aspect can improve the joint strength between the trim body and the fastening portion.

[Aspect 5]
As illustrated in FIG. 11A, the surface 11 of the foam material layer 10 may have a recess 12 that is recessed in a state where the bottom surface 32 of the main body 30 is in contact with the surface 11. The ratio Da / T0 of the depth Da of the recess 12 to the thickness T0 of the foam material layer 10 may be 0.5 or less. When Da / T0 ≦ 0.5, the strength of the foam material layer 10 in which the protruding portion (50) is inserted is good. Therefore, this embodiment is for a vehicle having a good joint strength between the trim body and the fastening portion. Interior members can be provided.

[Aspect 6]
As illustrated in FIG. 11B, the bottom surface 32 of the main body 30 is separated from the surface 11 of the foam material layer 10 at a distance Db lower than the height H1 of the protrusion (50) from the bottom surface 32. You may be doing it. The ratio Db / T0 of the interval Db to the thickness T0 of the foam material layer 10 may be 0.5 or less. When Db / T0 ≦ 0.5, the protruding portion (50) is easily caught by the foam material layer 10. Therefore, in this embodiment, the interior member for a vehicle having a good joint strength between the trim body and the fastening portion. Can be provided.

[Aspect 7]
By the way, the manufacturing method according to one aspect of the present technology is the manufacturing method of the vehicle interior member 1. The vehicle interior member 1 is a fastening portion 3 between a trim body 2 having a foam material layer 10 and the vehicle interior member 1 and a mating member (for example, a vehicle body panel 80), and is harder than the foam material layer 10. The fastening portion 3 of the above is provided. The fastening portion 3 includes a main body portion 30 having a bottom surface 32 and a plurality of projecting portions (for example, hooks 50) protruding from the bottom surface 32. The protruding portion (50) is formed in a direction different from the base portion 60 connected to the bottom surface 32 and the protruding direction D0 of the base portion 60 from the bottom surface 32 (for example, the first direction D1 and the second direction D2). It includes a protrusion 70 protruding from 60. In this manufacturing method, the plurality of fastening portions 3 are pressed against the surface 11 of the foam material layer 10 with the bottom surface 32 facing the surface 11 of the foam material layer 10 (for example, the back surface 2b of the trim body 2). The step (for example, the joining step ST1) of inserting the protruding portion (50) into the foam material layer 10 is included.

In the above aspect 6, a plurality of projecting portions (50) protruding from the bottom surface 32 of the fastening portion 3 enter the foam material layer 10 of the trim body 2, and the projecting direction D0 of the base 60 is formed on the plurality of projecting portions (50). Since there are protrusions 70 protruding from the base 60 in different directions (D1, D2), the trim body 2 and the fastening portion 3 are strong even if the main body 30 of the fastening portion 3 is not embedded in the foam material layer 10. It is joined to. Therefore, this aspect can provide a method for manufacturing an interior member for a vehicle in which a fastening portion is firmly joined to the trim body without using a separate member such as a cushion material or a seat material.

(2) Specific examples of vehicle interior members:
FIG. 1 schematically shows the interior of the automobile 100 as an example in a state where the side surface portion is not shown. FIG. 2 schematically shows the back surface 2b of the door trim 111 as an example of the vehicle interior member. FIG. 3 schematically shows the fastening portion 3 as the clip mounting seat and its periphery. FIG. 4 schematically illustrates a cross section when the fastening portion 3 and its periphery are cut at the position A1 in FIG. FIG. 5A schematically shows an example of a clip attached to the fastening portion 3 as a clip attachment seat. FIG. 5B is a cross-sectional view schematically illustrating a main part of an automobile 100 having a hooking portion 3A, which is an example of the fastening portion 3. In these figures, FRONT, REAR, UP, and DOWN indicate front, back, top, and bottom, respectively. Further, reference numeral D5 indicates a front-rear direction of the automobile 100, reference numeral D6 indicates a vertical direction of the automobile 100, and reference numeral D7 indicates a thickness direction of the vehicle interior member 1.

The automobile 100 shown in FIG. 1 is a road-traveling automobile designed and equipped for use on a road. For example, a metal body panel 80 (see FIGS. 5A and 5B) made of steel plate is used as a passenger compartment SP1 and a vehicle compartment SP1. The vehicle body is formed by surrounding the luggage compartment SP2. Further, the automobile 100 shown in FIG. 1 is a wagon type passenger automobile having a rear luggage compartment SP2 connected to the passenger compartment SP1 and having two rows of seats 101 (front seat and rear seat). Of course, automobiles to which this technology can be applied include automobiles other than the two-row seat type such as the three-row seat type, and include so-called station wagons, one-box cars and the like, as well as sedans and the like.

Various interior members 1 are arranged on the interior (SP1, SP2) side of the vehicle body panel 80 of the automobile 100. A door trim 111 (example of the interior member 1) is installed on the vehicle interior SP1 side of the door panel (example of the vehicle body panel 80) on the side of the vehicle interior SP1. On the deck side panel (example of the vehicle body panel 80) on the side of the luggage compartment SP2, a deck side trim 112 (example of the interior member 1) is installed on the luggage compartment SP2 side. Pillars 113 (example of interior member 1) are installed on the side of the vehicle interior SP1 on the pillars (example of the vehicle body panel 80) on the side of the vehicle interior SP1. Roof trim 114 (example of interior member 1) is installed on the interior (SP1, SP2) side of the roof panel (example of vehicle body panel 80) above the passenger compartment SP1 and luggage compartment SP2. A rear door trim 115 (example of interior member 1) is installed on the door panel (example of vehicle body panel 80) of the rear door (Tailgate) 105 behind the luggage compartment SP2 on the luggage compartment SP2 side. The vehicle body panel 80 is an example of a mating member 90 with respect to an interior member having a clip mounting seat.

The door trim 111 shown in FIG. 2 includes a trim main body 2 and a plurality of fastening portions 3. The trim main body 2 has an interior surface 2a facing the vehicle interior SP1 as shown in FIG. 1 and a back surface 2b to which the fastening portion 3 is fixed as shown in FIG. The back surface 2b is a surface of the door trim 111 opposite to the interior surface 2a and faces the outside of the vehicle. The door trim 111 has an uneven shape of the door panel and an uneven shape corresponding to the required shape of the vehicle interior SP1. The trims 112 to 115 also include a trim body 2 similar to the door trim 111, and a plurality of fastening portions 3.

3 and 4 illustrate the main parts of the interior member 1 including the trims 111 to 115.
The trim body 2 of the interior member 1 shown in FIGS. 3 and 4 has a foam material layer 10 including a back surface 2b and a skin material 20 having an interior surface 2a.

As the foamed material layer 10, a foamed resin molded body formed by foaming a resin material so as to contain air bubbles (air Ar) can be used. For example, injection molding can be used for foam molding of the resin material. As long as the above-mentioned resin material contains a thermoplastic material such as a thermoplastic resin, various synthetic resins (including elastomers) can be used, and additives may be added. As the above-mentioned thermoplastic resin, a polyolefin resin such as polypropylene (PP) resin or polyethylene (PE) resin, polystyrene (PS) resin, a combination thereof, or the like can be used, and an additive such as a filler is included. May be good. For foaming of the resin, physical foaming that dissolves the gas pressurized in the cylinder in the molten resin, chemical foaming that adds a chemical foaming agent and mixes the gas into the molten resin by thermal decomposition or chemical reaction, etc. are adopted. be able to. Foaming agents include volatile foaming agents that generate hydrocarbons such as butane and pentane, organic foaming agents such as azodicarbonamide (ADCA) and hydrazodicarbonamide, and inorganic foaming agents that generate carbon dioxide gas such as ammonium carbonate. , Etc. can be used.

The foaming ratio of the foam material layer 10 can be, for example, 2 to 50 times, more preferably 3 to 40 times, still more preferably 4 to 30 times.
The thickness T0 of the foam material layer 10 can be set to, for example, a height H1 or more and 8 mm or less of the hook 50 of the fastening portion 3 from the viewpoint of being lightweight and obtaining the required rigidity. The basis weight of the foam material layer 10 can be, for example, 450 to 1200 g / m ² from the viewpoint of being lightweight and obtaining the required rigidity.

As the skin material 20, non-woven fabric, woven fabric, knitted fabric, carpet, synthetic resin (including elastomer), rubber, and the like can be used. A backing (lining layer) may be formed on the back surface of the skin material 20. A synthetic resin (including an elastomer) such as a thermoplastic resin can be used for the backing. As the thermoplastic resin, a low melting point thermoplastic resin such as low density polyethylene or ethylene vinyl acetate can be used.

The fastening portion 3 shown in FIGS. 2 to 4 is a clip mounting seat that is harder than the foam material layer 10, and is used to attach an elastic clip 500 (see FIG. 5A) for fixing the interior member 1 to the vehicle body such as the vehicle body panel 80. It is a functional part of. The fastening portion 3 holds the base end of the clip 500 shown in FIG. 5A from the upper flange 503 to the lower flange 505. As the resin material for forming the fastening portion 3, various synthetic resins (including elastomers) can be used, additives may be added, and from the viewpoint of ease of molding, a thermoplastic resin such as a thermoplastic resin can be used. Resin materials are preferred. As the above-mentioned thermoplastic resin, polyolefin resins such as PP resin and PE resin, polyester resins such as acrylonitrile butadiene styrene (ABS) resin and polyethylene terephthalate (PET) resin, combinations thereof, and the like can be used, and fibers and the like can be added. The agent may be included. As the above-mentioned fibers, inorganic fibers such as glass fibers and carbon fibers, plant fibers such as kenaf, combinations thereof, and the like can be used. When the fastening portion 3 is made of a non-foaming resin molded body, the fastening portion 3 becomes harder than the resin foam material layer 10. Even if the fastening portion 3 is a foamed resin molded product, if the foaming ratio of the fastening portion 3 is lower than the foaming ratio of the resin foam material layer 10, the fastening portion 3 is harder than the resin foam material layer 10. Become. Further, the fastening portion 3 may be made harder than the foaming material layer 10 by using a resin that is harder than the resin material used for the foaming material layer 10 for the fastening portion 3. Further, in the fastening portion 3 shown in FIGS. 3 and 4, a resin material having a relatively high melting point such as polyester resin is used for a part of the bottom portion 31 and the hook 50, and a resin material having a relatively low melting point such as polyolefin resin is used for the remaining portion. May be used.

The fastening portion 3 shown in FIGS. 3 and 4 includes a main body portion 30 having a bottom surface 32 in contact with the surface 11 of the foam material layer 10, and a plurality of hooks 50 protruding from the bottom surface 32 into the foam material layer 10. .. The bottom surface 32 shown in FIGS. 3 and 4 is an example of a bottom surface facing the surface of the foam material layer. The hook 50 is an example of a protrusion. The main body 30 includes a bottom 31 having the above-mentioned bottom surface 32, a head 41 separated from the bottom 31 in the thickness direction D7, and a side wall 44 connected from the bottom 31 to the head 41 leaving an opening 30o. Includes ~ 46. There is a space 33 between the bottom 31 and the head 41. The space 33 is connected to the opening 30o and is between the left side wall portion 44 and the right side wall portion 46. The back side wall portion 45 is connected from the left side wall portion 44 to the right side wall portion 46. The head 41 has a through hole 42 for inserting the leg portion 504 of the clip 500 shown in FIG. 5A through the insertion port 43. The insertion port 43 is connected to the opening 30o, and the through hole 42 is connected to the space 33. Therefore, the space is surrounded by the bottom portion 31, the head portion 41, and the side wall portions 44 to 46, except for the portion from the opening 30o to the through hole 42. In this specific example, the holding portion 40 for holding the clip 500 includes a head portion 41 and side wall portions 44 to 46.

The clip 500 shown in FIG. 5A has an elastic clip head 501, a dish-shaped seal piece 502, a disc-shaped upper flange 503, and a columnar leg portion 504 in the order from the outside of the vehicle to the inside (SP1, SP2). It also has a disc-shaped lower flange 505. The clip 500 is made of resin, for example, and is formed by molding a resin material such as a thermoplastic resin. When the lower flange 505 is inserted into the space 33 through the opening 30o of the fastening portion 3, both flanges 503 and 505 sandwich the head portion 41 and the leg portion 504 penetrates the through hole 42. As a result, the base end of the clip 500 is held by the holding portion 40, and the clip 500 is attached to the fastening portion 3.
The clip 500 held in the fastening portion 3 engages with the vehicle body panel 80 (example of the mating member 90) by being inserted into the through hole 81 of the vehicle body panel 80. As a result, the interior member 1 is attached to the vehicle body panel 80 via the clip 500.

The fastening portion 3 is not limited to the clip mounting seat, and may be a portion for mounting the mating member 90 on the interior member 1. FIG. 5B schematically illustrates a cross section of the hook portion 3A included in the fastening portion 3 and its periphery in the automobile 100. The hooking portion 3A is a fastening portion 3 for attaching the mating member 90 to the interior member 1. For example, when the wire harness 85 (example of the mating member 90) is hooked and fixed to the hooking portion 3A, the wire harness 85 is attached to the interior member 1.

FIG. 6 schematically illustrates the bottom portion 31 and the hook 50 of the fastening portion 3. An enlarged view of the bottom surface 32 and the hook 50 is shown at the bottom of FIG. FIG. 7 schematically illustrates the hook 50 as viewed from the direction along the bottom surface 32. FIG. 8 schematically illustrates the hook 50 as viewed from a direction orthogonal to the bottom surface 32. Note that FIG. 8 shows the hook 50 in the foam material layer 10 in a state where the foam material layer 10 is not shown.

As shown in FIG. 6, the plurality of hooks 50 are arranged on the bottom surface 32 in a substantially first direction D1 and in a staggered manner in the third direction D3 substantially orthogonal to the first direction D1. The directions D1, D2, and D3 shown in FIG. 6 are based on the shape of the hook 50 before being inserted into the foam material layer 10. When the hook 50 is inserted into the foam material layer 10, the directions D1 to D3 may deviate from the directions shown in FIG.
Of course, the arrangement of the plurality of protrusions exemplified in the plurality of hooks 50 is not limited to the arrangement shown in FIG. 6, and is regularly arranged in two directions, the third direction D3 and the direction orthogonal to the third direction D3. It may be arranged side by side.

The hooks 50 shown in FIGS. 6 to 8 include a base portion 60 connected to the bottom surface 32 and a protruding portion 70 protruding from the base portion 60 in directions D1 and D2 different from the protruding directions D0 of the base portion 60 from the bottom surface 32. I'm out.
The bulge 70 came out of the base 60 in the first direction bulge 71 protruding from the base 60 in the first direction D1 and in the second direction D2 different from the first direction D1 when projected onto the bottom surface 32. The second direction protrusion 72 is included. That is, each hook 50 includes a first-direction protrusion 71 and the second-direction protrusion 72 that are oriented in different directions from each other. Here, the directions D1 to D3 when projected onto the bottom surface 32 mean the directions on the bottom surface 32 when viewed from a direction orthogonal to the bottom surface 32 as shown in FIG. The directions D1 and D2 when projected onto the bottom surface 32 are substantially opposite to each other. Here, the direction along the bottom surface 32 that intersects the first direction D1 and the second direction D2 when projected onto the bottom surface 32 is referred to as the third direction D3.

The base portion 60 is a first section 61 connected from the bottom surface 32 to the first direction protrusion 71, and a second section 62 located in the first section 61 to the third direction D3 and connected from the bottom surface 32 to the second direction protrusion 72. , And a third section 63 between the first section 61 and the second section 62. The first-direction protrusion 71 and the second-direction protrusion 72 are separated from each other in the third direction D3. That is, there is a gap CL1 between the first-direction protrusion 71 and the second-direction protrusion 72.

From the above, each hook 50 is a first-direction hook in which the first division 61 and the first-direction protrusion 71 are combined, and a second direction in which the second division 62 and the second-direction protrusion 72 are combined. Includes hooks. As shown in FIG. 7, the first-direction hook projects from the bottom surface 32 in the projecting direction D01 inclined toward the first-direction projecting portion 71 in the first section 61, and gradually bottoms out in the first-direction projecting portion 71. It protrudes from the first division 61 in the first direction D1 that turns toward 32. Therefore, in the first-direction protrusion 71, the tip 71e is different from the highest top 71t with respect to the bottom surface 32. The first-direction protrusion 71 has a recess 71d facing the bottom surface 32. The tip 71e, the top 71t, and the recess 71d are curved. Further, the second direction hook protrudes from the bottom surface 32 in the projecting direction D02 inclined toward the second direction projecting portion 72 in the second section 62, and gradually bends toward the bottom surface 32 in the second direction projecting portion 72. It protrudes from the second section 62 to the second direction D2. Therefore, in the second-direction protrusion 72, the tip 72e is different from the highest top 72t with respect to the bottom surface 32. The second-direction protrusion 72 has a recess 72d facing the bottom surface 32. The tip 72e, the top 72t, and the recess 72d are curved.

The concept of the protruding directions D01 and D02 is included in the concept of the protruding direction D0. By design, the first-direction hook and the second-direction hook have the same shape, the height of the tip 71e is the same as the height of the tip 72e, and the height of the top 71t is the same as the height of the top 72t. The heights H1 of the tops 71t and 72t are equal to or less than the thickness T0 of the foam material layer 10 (see FIG. 4), preferably 0.2 to 0.8 times the thickness T0, and 0.3 to 0.3 to the thickness T0. 0.7 times is more preferable.

Further, the maximum width W1 of the hook 50 in the direction along the bottom surface 32 is, for example, 0.6 to 2.0 of the height H1 from the viewpoint of improving the bonding strength between the foam material layer 10 and the fastening portion 3. It can be doubled, preferably 0.8 to 1.7 times the height H1, and more preferably 1.0 to 1.4 times the height H1. When the fastening portion 3 is joined to the molded foam material layer 10, the width W1 is preferably in the above-mentioned numerical range from the viewpoint of easily inserting a plurality of hooks 50 into the foam material layer 10.

Further, the thickness T1 of the first-direction protrusion 71 and the first section 61, and the thickness T2 of the second-direction protrusion 72 and the second section 62 join the foam material layer 10 and the fastening portion 3. From the viewpoint of improving the strength, for example, it can be 0.1 to 1.0 mm, preferably 0.2 to 0.8 mm. The thickness T3 of the third division 63 can be, for example, 0.1 to 1.0 mm from the viewpoint of improving the joint strength between the foam material layer 10 and the fastening portion 3, and is 0.2 to 0. 8 mm is preferable.

The number of protrusions such as hooks 50 arranged on the bottom surface 32 is ^{40 to 200 per 900 mm 2} (a square area of 30 mm on a side) from the viewpoint of improving the joint strength between the foam material layer 10 and the fastening portion 3. it can be a book, preferably 900 mm ² 60 to 180 fibers per are, 80 to 160 fibers per 900 mm ² is more preferable.

FIG. 9 schematically illustrates a state in which the hook 50 contained in the foam material layer 10 is viewed from a direction orthogonal to the third direction D3 along the bottom surface 32 in a state where the fastening portion 3 is joined to the trim body 2. doing. In the interior member 1 shown in FIG. 9, the gap CL1 between the first-direction protrusion 71 and the second-direction protrusion 72 widens as the distance from the bottom surface 32 increases. In this case, as shown in FIG. 8, in the hook 50 contained in the foam material layer 10, the first direction D1 in which the first direction protrusion 71 protrudes and the second direction D1 in which the second direction protrusion 72 protrudes. The bidirectional D2 is a direction away from the third division 63 of the base 60 when projected onto the bottom surface 32.
From the above, the joint strength between the foam material layer 10 and the fastening portion 3 is high in the thickness direction D7 of the interior member 1.

Here, as shown in FIG. 6, the combined volume of all the hooks 50 protruding from the bottom surface 32 is V1 (mm ³ ), and the combined surface area of all the hooks 50 protruding from the bottom surface 32 is S1 (mm ² ). And. The volume V1 means the total ^{volume V2 (mm 3} ) of each hook 50 protruding from the bottom surface 32. ^{The surface area S1 means the total surface area S2 (mm 2} ) of each hook 50 protruding from the bottom surface 32, and does not include the area of the portion of each hook 50 connected to the bottom surface 32. The ratio of the total surface area S1 (mm ² ) of the hook 50 to the total volume V1 (mm ³ ) of the hook 50 S1 / V1 (mm ^-1 ) improves the joint strength between the trim body 2 and the fastening portion 3. From the point of view, 10 or less is preferable, 9 or less is more preferable, and 8 or less is further preferable. Further, from the viewpoint of facilitating the molding of the hook 50, the above-mentioned ratio S1 / V1 (mm ^-1 ) is preferably 1 or more, more preferably 2 or more, still more preferably 3 or more.

As will be described in detail later, when the bottom surface 32 of the main body 30 of the fastening portion 3 is pressed against the surface 11 of the foam material layer 10 in the thickness direction D7 as illustrated in FIG. 10 to form the interior member 1, A recess 12 as illustrated in FIG. 11A may be formed on the surface 11 of the foam material layer 10. An enlarged view of a main part of the trim body 2 having the recess 12 is shown in the lower part of FIG. 11A.

The surface 11 of the foam material layer 10 shown in FIG. 11A has a recess 12 that is recessed in a state where the bottom surface 32 of the main body 30 of the fastening portion 3 is in contact with the surface 11. Here, the ratio Da / T0 of the depth Da of the recess 12 to the thickness T0 of the foam material layer 10 is preferably 0.5 or less, more preferably 0.4 or less, still more preferably 0.3 or less. When the ratio Da / T0 is equal to or less than the above-mentioned value, the strength of the foam material layer 10 in which the hook 50 is inserted is good. Therefore, when the tensile test of the fastening portion 3 is performed, the foam material layer 10 is combined with the fastening portion 3. Peeling is suppressed, and the joint strength between the trim body 2 and the fastening portion 3 is good.

Further, when the force of pressing the main body portion 30 of the fastening portion 3 against the surface 11 of the foam material layer 10 is weakened, as illustrated in FIG. 11B, the bottom surface 32 of the main body portion 30 has an interval Db lower than the height H1 of the hook 50. In some cases, the foam material layer 10 is separated from the surface 11. Here, the ratio Db / T0 of the interval Db to the thickness T0 of the foam material layer 10 is preferably 0.5 or less, more preferably 0.4 or less, still more preferably 0.3 or less. When the ratio Db / T0 is equal to or less than the above-mentioned numerical value, the hook 50 is well hooked on the foam material layer 10, so that the joint strength between the trim body 2 and the fastening portion 3 is good. Further, by limiting the force for pressing the main body portion 30, it is possible to prevent the trace of pressing from the main body portion 30 from being generated on the indoor surface 2a of the trim main body 2.

(3) Specific examples of methods for manufacturing interior members for vehicles, as well as actions and effects:
The foamed material layer 10 is formed, for example, by injecting a molten resin material into a mold having a mold surface having a required shape, foaming the resin material, and cooling the mold. When the skin material 20 is attached to the indoor surface 2a side of the foam material layer 10, the trim body 2 is formed. Further, the trim body 2 is formed by putting the skin material 20 in the mold so that the molten resin material does not wrap around the indoor surface 2a, injecting the molten resin material, foaming the resin material, and cooling the mold. It is also possible to form.

The fastening portion 3 is formed, for example, by injecting a molten resin material into a mold in which an insert die is fitted into a master block and having a mold surface having a required shape, and cooling the mold. Will be done. The nesting mold is a partial mold that is used by fitting it into a mother mold, and may be a movable type, which is also called a slide type, or a fixed type. Further, in the fastening portion 3, a resin material having a relatively high melting point (for example, a melting point of 220 ° C. or higher) such as PET resin is used for a part of the bottom portion 31 and the hook 50, and a relatively low melting point (for example, PP resin) is used for the remaining portion. For example, a resin material having a melting point of 200 ° C. or lower may be used. In this case, a part of the bottom portion 31 and the molded sheet to be the hook 50 can be formed by injection molding, extrusion molding, or the like. For example, a molded sheet is molded by injecting a molten resin material into a mold having a mold surface having a required shape and cooling the mold. The fastening portion 3 is formed, for example, by inserting a molding sheet into a mold so that the molten resin material does not wrap around the plurality of hooks 50, injecting the molten resin material, and cooling the mold.

FIG. 10 schematically illustrates a joining step ST1 for joining the fastening portion 3 to the trim body 2. In the joining step ST1, a plurality of hooks 50 are pressed against the surface 11 of the foam material layer 10 in the thickness direction D7 by pressing the fastening portion 3 with the bottom surface 32 facing the surface 11 of the foam material layer 10. Insert in. Then, as shown in FIGS. 4, 11A and 11B, the bottom surface 32 of the fastening portion 3 is maintained in a state of facing the surface 11 of the foam material layer 10, and the hooks 50 of the plurality of hooks 50 contained in the foam material layer 10 are maintained. The protruding portion 70 prevents the fastening portion 3 from being separated from the trim body 2 in the thickness direction D7. Further, by inserting the hook 50 having the gap CL1 between the first-direction protrusion 71 and the second-direction protrusion 72 into the foam material layer 10, the portion of the foam material layer 10 that enters the gap CL1 is the gap CL1. In the third direction D3. As a result, as shown in FIG. 9, the first-direction protrusion 71 and the second-direction protrusion 72 are separated from each other as they are separated from the bottom surface 32.

From the above, the fastening portion 3 is firmly joined to the trim body 2 in the thickness direction D7 of the interior member 1. On the other hand, the bottom portion 31 of the fastening portion 3 is not embedded in the foam material layer 10. Therefore, this specific example can provide an interior member for a vehicle in which a fastening portion is firmly joined to the trim body without using a separate member such as a cushion material or a seat material. In particular, as shown in FIG. 9, the gap CL1 between the first-direction protrusion 71 and the second-direction protrusion 72 widens as the distance from the bottom surface 32 increases, so that the foam material layer 10 in the thickness direction D7 The joint strength between the and the fastening portion 3 is high.

(4) Modification example:
Various modifications of the present invention can be considered.
For example, the vehicle interior member to which the present technology can be applied may be a deck side trim 112, a pillar trim 113, a roof trim 114, a rear door trim 115, a trunk interior material, or the like, in addition to the door trim 111.

The fastening portion is not limited to the clip mounting seat shown in FIGS. 2 to 4. Explaining using the reference numerals shown in FIGS. 3 and 4, the side wall portions 44 to 46 of the fastening portion 3 are not limited to being connected so as to be bent, and may be connected in a curved surface shape. Further, the bottom portion 31 of the fastening portion 3 may extend outward from the side wall portions 44 to 46. Here, along the bottom surface 32, the side from the side wall portions 44 to 46 where the space 33 exists is the inside, and the portion from the side wall portions 44 to 46 to the side opposite to the space 33 is the outside. When the bottom portion 31 is on the outside from the side wall portions 44 to 46, the bottom portion 31 may not be on the inside from the side wall portions 44 to 46. For example, the clip mounting seats 3B and 3C shown in FIGS. 12A and 12B can be used for the interior member 1. Here, the same reference numerals are given to the same configurations as those of the specific examples described above, and detailed description thereof will be omitted. The concept of the clip mounting seats 3B and 3C is included in the concept of the fastening portion 3.

The clip mounting seat 3B shown in FIG. 12A has a side wall portion 44 to 46 connected in a curved surface shape, and a bottom portion 31 extending outward from the side wall portion 44 to 46 and not inside from the side wall portion 44 to 46. There is. In this case, the bottom surface (not shown) of the clip mounting seat 3B is on the outside from the side wall portions 44 to 46, and a plurality of hooks protruding from the side wall portions 44 to 46 on the outside are arranged. As a result, the bottom surface can be made wider than that of the fastening portion 3 shown in FIGS. 2 to 4, the number of hooks can be increased, and the joint strength between the trim body 2 and the fastening portion 3 can be increased. ..

The clip mounting seat 3C shown in FIG. 12B has side wall portions 44 to 46 connected in a curved surface shape, and a bottom portion 31 extending from the inside to the outside of the side wall portions 44 to 46. In this case, the bottom surface (not shown) of the clip mounting seat 3C is from the inside to the outside of the side wall portions 44 to 46, and a plurality of hooks protruding from the inside to the outside of the side wall portions 44 to 46 are arranged. .. As a result, the required area is smaller than that of the clip mounting seat 3B shown in FIG. 12A.

Further, the protruding portion is not limited to the hook 50 shown in FIGS. 6 to 9. Explaining using the reference numerals shown in FIGS. 6 to 9, the second direction hook (second section 62 and the second direction protrusion 72) is the first direction hook (first section 61 and the first direction protrusion 72). The shape may be different from 71). The bulge 70 may include a third directional ledge protruding from the base 60 in a direction different from both the first direction D1 and the second direction D2 from the base 60. Further, the base portion 60 may not have the third division 63, and the hook 50 may not have the second direction protrusion 72, the second division 62, and the third division 63. Further, the projecting portions 50A and 50B illustrated in FIGS. 13A and 13B may project from the bottom surface 32 into the foam material layer 10.

The protrusion 50A shown in FIG. 13A has a columnar (for example, columnar) base 60 protruding from the bottom surface 32 and a protrusion protruding from the tip of the base 60 in a direction different from the protrusion direction D0 of the base 60 from the bottom surface 32. A part 70 and the like are included. The protrusion 50B shown in FIG. 13B has a columnar (for example, columnar) base 60 protruding from the bottom surface 32 and a protrusion protruding from the middle of the base 60 in a direction different from the protrusion direction D0 of the base 60 from the bottom surface 32. A part 70 and the like are included. The protruding direction D0 of the base 60 shown in FIGS. 13A and 13B is a direction orthogonal to the bottom surface 32, but the protruding direction D0 of the base 60 may be a direction deviated from the direction orthogonal to the bottom surface 32. The direction in which the protrusion 70 shown in FIGS. 13A and 13B protrudes from the base 60 is the direction along the bottom surface 32, but the direction in which the protrusion 70 protrudes from the base 60 is a direction deviated from the direction along the bottom surface 32. But it may be.

The ratio S1 / V1 (mm ^-1 ) in the protruding portions 50A and 50B is preferably 10 or less, more preferably 9 or less, and even more preferably 8 or less, as in the case of the hook 50. Further, the above-mentioned ratio S1 / V1 (mm ^-1 ) is preferably 1 or more, more preferably 2 or more, and even more preferably 3 or more. The ratio Da / T0 of the depth Da of the recess 12 which is recessed in the state where the bottom surface 32 where the plurality of protrusions 50A and 50B are protruding is also preferably 0.5 or less, more preferably 0.4 or less. , 0.3 or less is more preferable. The ratio Db / T0 of the interval Db when the bottom surface 32 of the main body 30 is separated from the surface 11 of the foam material layer 10 by the interval Db is also preferably 0.5 or less, more preferably 0.4 or less, and 0. 3 or less is more preferable.

Further, in the above-mentioned example, the fastening portion 3 is joined to the trim body 2 by inserting the protruding portion into the foaming material layer 10, but the foaming material layer 10 is formed by putting the fastening portion 3 in a mold and foaming the molten resin. By injection molding, the fastening portion 3 may be joined to the foam material layer 10 at the same time as the foam material layer 10 is molded.

(5) Example:
Hereinafter, the present invention will be specifically described with reference to examples, but the present invention is not limited to the following examples.

As the sample of the foam material layer 10, a PP foam resin having a thickness T0 = 3.0 mm and a foaming ratio of 6 times was used. PET resin was used as a sample of the bottom portion 31 of the fastening portion 3 and the hook 50. The shape of the bottom sample is as shown in FIGS. 6 and 7, the height H1 in the mold shape of each hook 50 was 2.3 mm, and the height H1 of each hook 50 after molding was 2.5 mm.

[Example 1]
A bottom sample having 144 hooks 50 was formed on a square bottom surface 32 having a side of 30 mm. The total volume V1 of ^{the hook 50 was 281.808 mm 3} , and the total surface area S1 of the hook 50 was ^{2004.48 mm 2.} The ratio S1 / V1 is 7.11 mm ^-1 . By pressing each hook 50 of the obtained bottom sample against the surface 11 of the foam material layer 10, there is no recess 12 (see FIG. 11A), that is, the ratio Da / T0 = 0.00 and the ratio Db / T0. An interior member sample with = 0.00 was prepared.

[Example 2]
By pressing each hook 50 of the same bottom sample as in Example 1 against the surface 11 of the foam material layer 10, Da = 1.0 mm, that is, the ratio Da / T0 = 0.29, against the surface 11 of the foam material layer 10. An interior member sample having the recess 12 was prepared.

[Example 3]
A bottom sample having 170 hooks 50 was formed on a square bottom surface 32 having a side of 30 mm. The total volume V1 of ^{the hook 50 was 288.66 mm 3} , and the total surface area S1 of the hook 50 was ^{228.3 mm 2.} The ratio S1 / V1 is 7.65 mm ^-1 . By pressing each hook 50 of the obtained bottom sample against the surface 11 of the foam material layer 10, Da = 1.0 mm, that is, the recess 12 having a ratio of Da / T0 = 0.29 to the surface 11 of the foam material layer 10. An interior member sample having the above was prepared.

[Example 4]
A bottom sample having 144 hooks 50 was formed on a square bottom surface 32 having a side of 30 mm. The total volume V1 of ^{the hook 50 was 207.072 mm 3} , and the total surface area S1 of the hook 50 was ^{2180.16 mm 2.} The ratio S1 / V1 is 10.53 mm ^-1 . By pressing each hook 50 of the obtained bottom sample against the surface 11 of the foam material layer 10, there is no recess 12, that is, at a ratio of Da / T0 = 0.00 and a ratio of Db / T0 = 0.00. A sample of an interior member was prepared.

[Tension test evaluation device]
FIG. 14 schematically illustrates an evaluation device 600 for evaluating the joint strength between the trim body 2 and the bottom portion 31 (fastening portion 3). The trim body 2 of the interior member sample is fixed to a fixture (not shown), and a hole 2h through which the bolt 631 is passed is formed. The bottom portion 31 and the evaluation device plate 610 are fixed to each other by the bolt 631 and the nut 632 through which the bolt 631 is passed through the hole 2h. Both ends of the string 620 for applying the tensile force F1 are fixed to the bolt 631 between the bottom 31 and the plate 610.
The interior member samples of Examples 1 to 4 were set in the evaluation device 600, and the test of applying a tensile force of F1 = 220N was repeated 10 times.

表１に示すように、比Ｓ１／Ｖ１が１０よりも大きい実施例４の内装部材サンプルの場合、該サンプルは内装部材として使用可能であるが、Ｆ１＝２２０Ｎの引っ張り力を加えた時にトリム本体２からの底部サンプルの剥離が見られた。一方、比Ｓ１／Ｖ１が１０以下である実施例１〜３の内装部材サンプルの場合、Ｆ１＝２２０Ｎの引っ張り力を加える試験を繰り返し１０回行っても、底部サンプルはトリム本体２から剥離しなかった。従って、Ｓ１／Ｖ１≦１０にすることによりトリム本体２と締結部３との接合強度が向上することが分かった。 [result]
Table 1 shows the evaluation results of the tensile test.

As shown in Table 1, in the case of the interior member sample of Example 4 in which the ratio S1 / V1 is larger than 10, the sample can be used as the interior member, but the trim body is trimmed when a tensile force of F1 = 220N is applied. Peeling of the bottom sample from 2 was observed. On the other hand, in the case of the interior member samples of Examples 1 to 3 in which the ratio S1 / V1 is 10 or less, the bottom sample does not peel off from the trim body 2 even if the test of applying a tensile force of F1 = 220N is repeated 10 times. It was. Therefore, it was found that the joint strength between the trim body 2 and the fastening portion 3 is improved by setting S1 / V1 ≦ 10.

(6) Conclusion:
As described above, according to the present invention, according to various aspects, a vehicle interior member or the like in which a fastening portion such as a clip mounting seat is firmly joined to the trim body without using a separate member such as a cushion material or a seat material. Technology can be provided. Of course, the above-mentioned basic actions and effects can be obtained even with a technique consisting of only the constituent requirements according to the independent claims.
In addition, the configurations disclosed in the above-mentioned examples are mutually replaced or the combinations are changed, the known techniques and the respective configurations disclosed in the above-mentioned examples are mutually replaced or the combinations are changed. It is also possible to implement the above-mentioned configuration. The present invention also includes these configurations and the like.

1 ... Interior material,
2 ... Trim body, 2a ... Indoor surface, 2b ... Back surface,
3 ... Fastening part, 3A ... Hooking part, 3B, 3C ... Clip mounting seat,
10 ... Foam material layer, 11 ... Surface, 12 ... Recess, 20 ... Skin material,
30 ... Main body, 31 ... Bottom, 32 ... Bottom, 33 ... Space, 40 ... Holding, 41 ... Head,
50 ... hook (example of protruding part), 50A, 50B ... protruding part,
60 ... base, 61 ... first division, 62 ... second division, 63 ... third division,
70 ... bulge, 71 ... first direction bulge, 72 ... second direction bulge,
80 ... Body panel, 85 ... Wire harness,
90 ... Opposite member,
100 ... car, 111 ... door trim,
CL1 ... Gap,
D0 ... projecting direction, D1 ... first direction, D2 ... second direction, D3 ... third direction,
D5 ... front-back direction, D6 ... up-down direction, D7 ... thickness direction,
ST1 ... Joining process.

Claims (7)

It is an interior member for vehicles
A trim body with a foam material layer and
A fastening portion between the vehicle interior member and the mating member, which is harder than the foam material layer, is provided.
The fastening part is
A main body having a bottom surface facing the surface of the foam material layer,
Includes a plurality of protrusions protruding from the bottom surface into the foam material layer.
The protrusion is
The base connected to the bottom surface and
Includes a protruding portion protruding from the base in a direction different from the protruding direction of the base from the bottom surface.
Interior materials for vehicles. The protrusions are a first-direction protrusion protruding from the base in the first direction and a second-direction protrusion protruding from the base in a second direction different from the first direction when projected onto the bottom surface. Including the tension part,
The protrusion includes the first direction protrusion and the second direction protrusion.
The vehicle interior member according to claim 1. The direction along the bottom surface and intersecting the first direction and the second direction when projected onto the bottom surface is defined as the third direction.
The base includes a first section that connects the bottom surface to the first-direction protrusion, and a second section that connects the first section to the third direction and connects the bottom surface to the second-direction protrusion. Including the third division between the first division and the second division,
The first-direction protrusion and the second-direction protrusion are separated in the third direction.
The vehicle interior member according to claim 2. Any of claims 1 to 3, wherein the ratio S1 / V1 (mm ^-1 ) of the surface areas S1 (mm ² ) of the plurality of protrusions to the volume V1 (mm ^{3) of the plurality of protrusions is 10 or less.} The vehicle interior member described in item 1. The surface of the foam material layer has a recess that is recessed in contact with the bottom surface of the main body.
The vehicle interior member according to any one of claims 1 to 4, wherein the ratio Da / T0 of the depth Da of the recess to the thickness T0 of the foam material layer is 0.5 or less. The bottom surface of the main body is separated from the surface of the foam material layer at a distance Db lower than the height of the protrusion from the bottom surface.
The vehicle interior member according to any one of claims 1 to 4, wherein the ratio Db / T0 of the interval Db to the thickness T0 of the foam material layer is 0.5 or less. It is a method of manufacturing interior parts for vehicles.
The vehicle interior member includes a trim body having a foam material layer, and a fastening portion between the vehicle interior member and a mating member, which is harder than the foam material layer.
The fastening portion includes a main body portion having a bottom surface and a plurality of projecting portions protruding from the bottom surface.
The protruding portion includes a base portion connected to the bottom surface and a protruding portion protruding from the base portion in a direction different from the protruding direction of the base portion from the bottom surface.
Manufacture of an interior member for a vehicle, which comprises a step of inserting the plurality of protruding portions into the foam material layer by pressing the fastening portion with the bottom surface facing the surface of the foam material layer against the surface of the foam material layer. Method.

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